com
2900 Industrial Parkway East n Elkhart, IN 46516
Phone: 574-295-7888 n Fax: 574-295-8666
ISO 9001:2015 Certified
Two Dexter philosophies are at work to provide you the best product
available and have enabled us to maintain our position of leadership. First,
we operate on the theory that “there is always a better way” for a product
to operate, to be manufactured, and/or to be serviced. We are constantly
striving to find that better way.
Table of Contents
Bearing Lubrication - Oil.......................................................................52
Recommended Wheel Bearing Lubrication Specifications...................53
Seal Inspection and Replacement........................................................55
Bearing Adjustment and Hub Replacement.........................................56
Typical E-Z Lube® After Spring 2002....................................................57
E-Z Lube® Lubrication..........................................................................57
Nev-R-Lube® Drums/Bearings......................................................................59
Drum Removal.....................................................................................60
Bearing Inspection...............................................................................60
Nev-R-Lube® Bearing End Play Inspection..........................................61
Bearing Replacement and Drum Installation........................................62
Axle Installation
Axle & Suspension Installation.....................................................................64
Suspensions
Suspension Systems....................................................................................65
Double Eye Leaf Springs......................................................................65
Grease Lubricated Suspension Bushings............................................66
Slipper Leaf Springs.............................................................................66
Inspection and Replacement................................................................67
Suspension Fastener Torque Values....................................................67
Torflex® Suspension..............................................................................69
Airflex® Suspension..............................................................................70
Wheels and Tires
Wheels.........................................................................................................72
Wheel Selection...................................................................................72
Torque Requirements...........................................................................73
Wheel Torque Requirements................................................................74
Maximum Wheel Fastener Torque........................................................75
Tires.............................................................................................................76
Tire Wear Diagnostic Chart..................................................................77
Replacement Parts/Kits
Magnet Replacement Kits and Brake Nut Torque................................78
Seal Replacement Reference..............................................................78
Brake Shoe Replacement Kits.............................................................79
Bearing Replacement Chart.................................................................80
Storage
Storage Preparation.....................................................................................81
After Prolonged Storage - Inspection Procedures........................................82
Trip Preparation Checklist.............................................................................83
Maintenance Schedule
Maintenance Schedule Chart.......................................................................84
Warranty
Limited Warranty...........................................................................................85
Axle Identification
Axle Identification.........................................................................................88
Video Gallery
Dexter Video Gallery....................................................................................90
Important Safety Notice
Appropriate service methods and repair procedures are essential
for the safe, reliable operation of all running gear as well as the
personal safety of the individual doing the work. This manual
provides general directions for performing service and repair work
with tested, effective techniques. Following these guidelines will
help assure reliability.
There are numerous variations in procedures, techniques, tools,
parts for servicing axles, as well as in the skill of the individual
doing the work. This manual cannot possibly anticipate all such
variations and provide advice or cautions as to each. Anyone who
departs from the instructions provided in this manual must first
establish that they neither compromise their personal safety nor
the vehicle integrity by their choice of methods, tools, or parts.
Refer to your vehicle manufacturer’s owners manual for additional
procedures, techniques, and warnings prior to performing any
maintenance or repairs.
! CAUTION
This is the safety alert symbol. It is used to alert you to
potential injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
-4-
Electric Brakes
Retractor Spring
Primary Shoe
Secondary Shoe
Front of Brake
Adjuster
Magnet
Adjuster Spring
When the electrical current is fed into the system by the controller,
it flows through the electromagnets in the brakes. The high
capacity electromagnets are energized and are attracted to the
rotating armature surface of the drums which moves the actuating
levers in the direction that the drums are turning.
The resulting force causes the actuating cam block at the shoe
end of the lever to push the primary shoe out against the inside
surface of the brake drum. The force generated by the primary
shoe acting through the adjuster moves the secondary shoe out
into contact with the brake drum.
Increasing the current flow to the electromagnet causes the
magnet to grip the armature surface of the brake drum more firmly.
This results in increasing the pressure against the shoes and
brake drums until the desired stop is accomplished.
-5-
Features
Electrically actuated brakes have several advantages over other
brake actuation systems.
1. They can be manually adjusted at the controller to provide
the correct braking capability for varying road and load
conditions.
2. They can be modulated to provide more or less braking
force, thus easing the brake load on the towing vehicle.
3. They have very little lag time from the moment the tow
vehicle’s brakes are actuated until the trailer brakes are
actuated.
4. In an emergency situation, they can provide some braking
independent of the tow vehicle.
-6-
Brake Controllers
-7-
Dexter Electric Brakes
Wired in parallel.
Braking Systems - Electric
Breakaway Battery
Provides power to actuate
trailer brakes in the event of
trailer breakaway.
Breakaway Switch
Switches battery power
to brakes if
breakaway occurs.
-8-
Braking Systems - Electric
Controller
Electric brake controller
provides power to the
magnets to actuate the
trailer brakes.
Battery
Connect controller directly.
Connector
Used to connect and disconnect
trailer and tow vehicle.
(Always ground trailer brakes
through connector).
-9-
Typical Trailer Wiring
Double
Filament Stop & Left Turn Signal
Bulb To Terminal #5
Green
Red
Yellow Auxiliary Circuit
License Tail & Terminal #7 White #1 Common Ground
Running Lights
Terminal #3 Grey Auxiliary Circuit Green #3 To Tail Running &
Terminal #8 License Lights
Red #5 Stop & Left Turn
Black #4 Battery Charge
Battery Charge Yellow #7 Aux. Circuit
Terminal #4 Black
Orange #9 Aux. Circuit
Brown #6 Stop & Right Turn
Blue #2 Electric Brake
Electric Brake Batt. Breakaway Switch
Terminal #2 Blue Grey #8 Aux. Circuit
Electric Brake White Common Ground
Ground Terminal Terminal #1
#1 White Orange
Brown
Auxiliary Circuit
Terminal #9
Double Stop & Right Turn Signal
Filament Terminal #6
Bulb
E
Clearance &
AC
R
G Ground
GR
K
ITE
1 3
Tail Lights
EE
YELLOW YELLOW
WH
Stop &
Braking Systems - Electric
BROWN
Stop &
N
RED
5 7 6 7
LH Turn RH Turn
Battery
CK
BLU
BLA
4
Brakes 2
Charge
E
W
E
H
U
IT
GR
BL
1 2 N
E
EY OW
Ground Brakes 8
BR
6 Stop &
Auxiliary RH Turn
Auxiliary
Auxiliary
-10-
How to Use Your Electric Brakes Properly
-11-
Synchronizing Your Trailer Brakes
To ensure safe brake performance and synchronization, read the
brake controller manufacturer’s instructions completely before
attempting any synchronization procedure.
! CAUTION
Before road testing, make sure the area is clear of
vehicular and pedestrian traffic. Failure to brake safely
could result in an accident and personal injury to
yourself and/or others.
Make several hard stops from 20 m.p.h. on a dry paved road free
of sand and gravel. If the trailer brakes lock and slide, decrease
the gain setting on the controller. If they do not slide, slightly
increase the gain setting. Adjust the controller just to the point of
impending brake lockup and wheel skid.
Note: Not all trailer brakes are capable of wheel lockup. Loading
conditions, brake type, wheel and tire size can all affect whether
a brake can lock. It is not generally considered desirable to lock
up the brakes and slide the tires. This can cause unwanted flat
spotting of the tires and could also result in a loss of control.
If the controller is applying the trailer brakes before the tow vehicle
Braking Systems - Electric
-12-
General Maintenance - Electric Brakes
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
! CAUTION
POTENTIAL ASBESTOS DUST HAZARD!
Some older brake linings may contain asbestos dust,
which has been linked to serious or fatal illnesses.
Certain precautions need to be taken when servicing
brakes:
1. Avoid creating or breathing dust.
2. Avoid machining, filing or grinding the brake linings.
3. Do not use compressed air or dry brushing for
cleaning (dust can be removed with a damp brush).
Braking Systems - Electric
Brake Lubrication
Before reassembling, apply a light film of grease or anti-seize
compound on the brake anchor pin, the actuating arm bushing
and pin, and the areas on the backing plate that are in contact
with the brake shoes and magnet lever arm. Apply a light film of
grease on the actuating block mounted on the actuating arm.
CAUTION
Do not get grease or oil on the brake linings, drums or
magnets.
-14-
Magnets
Straight Edge
NORMAL WEAR
-15-
Shoes and Linings
A simple visual inspection of your brake linings will tell if they are
usable. Replacement is necessary if the lining is worn to ¹⁄₁₆" or
less. Shoes contaminated
with grease or oil, or
abnormally scored or gouged
should also be replaced.
Hairline heat cracks are
normal in bonded linings
and should not be cause for
concern. When replacement
is necessary, it is important to
replace both shoes on each
brake and both brakes of
the same axle. This will help Acceptable
Hairline Cracks
retain the “balance” of your
brakes.
! CAUTION
POTENTIAL ASBESTOS DUST HAZARD!
Some older brake linings may contain asbestos dust,
which has been linked to serious or fatal illnesses.
Certain precautions need to be taken when servicing
Braking Systems - Electric
brakes:
1. Avoid creating or breathing dust.
2. Avoid machining, filing or grinding the brake linings.
3. Do not use compressed air or dry brushing for
cleaning (dust can be removed with a damp brush).
-16-
Introduction to Troubleshooting
Troubleshooting
Most electric brake malfunctions that cannot be corrected by either
brake adjustments or synchronization adjustments, can generally
be traced to electrical system failure. Voltmeters and ammeters
are essential tools for proper troubleshooting of electric brakes.
Mechanical causes are ordinarily obvious, i.e. bent or broken
parts, worn out linings or magnets, seized lever arms or shoes,
scored drums, loose parts, etc. Replace defective parts with
genuine Dexter replacements.
Please consult the following troubleshooting charts to determine
the causes and solutions for common problems found in trailer
braking systems.
! CAUTION
Best braking performance is achieved with a controller
setting that is just short of wheel lock up or slide. Overly
aggressive braking which results in wheel lock up and
sliding, can cause a dangerous loss of control and
result in personal injury or death.
-17-
Troubleshooting
SYMPTOM CAUSES REMEDIES
Open Circuits Find & Correct
Severe
No Brakes Underadjustment Adjust Brakes
Grease or Oil on
Magnets or Linings Clean or Replace
Worn Linings
or Magnets Replace
Underadjustment Adjust
Braking Systems - Electric
Improper Correct
Synchronization
Out-of-Round
Brake Drums Machine or Replace
-18-
Troubleshooting
Grease or Oil on
Linings or Magnets Clean or Replace
Brakes Pull to
One Side
Broken Wires Find & Repair
Underadjustment Adjust
Improper
Synchronization Correct
Harsh Brakes
Improper Controller Change
Underadjustment Adjust
Incorrect Brake
Components Correct
Overadjustment Readjust
Loose Wheel
Bearing Adjustment Adjust
-19-
How to Measure Voltage
System voltage is measured at the magnets by connecting the
voltmeter to the two magnet lead wires at any brake. This may be
accomplished by using a pin probe inserted through the insulation
of the wires. The engine of the towing vehicle should be running
when checking the voltage so that a low battery will not affect the
readings.
Voltage in the system
should begin at 0 volts
and, as the controller bar
is slowly actuated, should
gradually increase to about VOLTMETER
-20-
Magnet Amperes Chart
-21-
Finding the cause of a short circuit in the system is done by
isolating one section at a time. If the high amperage reading drops
to zero by unplugging the trailer, then the short is in the trailer. If
the amperage reading remains high with all the brake magnets
disconnected, the short is in the trailer wiring.
All electrical troubleshooting procedures should start at
the controller. Most complaints regarding brake harshness
or malfunction are traceable to improperly adjusted or
non‑functioning controllers. See your controller manufacturer’s
data for proper adjustment and testing procedures. For best
results, all the connection points in the brake wiring should be
sealed to prevent corrosion. Loose or corroded connectors will
cause an increase in resistance which reduces the voltage
available for the brake magnets.
Braking Systems - Electric
-22-
Hydraulic Brakes
CAUTION
The maximum operating pressure for Dexter brakes:
• 7" diameter drum brakes
maximum operating pressure is 750 psi
• 10" diameter and larger drum brakes
maximum operating pressure is 1,000 psi
• Hydraulic disc brakes (all sizes)
maximum operating pressure is 1,600 psi
-23-
Hydraulic Drum Brake Operation
Duo-Servo
The duo-servo brake uses a dual piston wheel cylinder to apply
the brakes. This type of brake is typically used in an electric/
hydraulic, vacuum/hydraulic, or air/hydraulic system. A description
of operation of this brake is as follows:
When the brakes are applied, the double-acting wheel cylinder
moves the primary and secondary shoes towards the drum. The
frictional force between the brake drum and lining attempts to
turn the primary
Anchor Post
shoe into the Hydraulic Wheel
Retractor
secondary shoe. Cylinder
Springs
The secondary
shoe is forced onto
the anchor pin and Backing Actuating Pin
Plate
from this point,
the secondary Hold Down
and primary Secondary Spring
shoes attempt to Shoe
“wrap around”.
Primary Shoe
In essence, the Adjuster Spring
brake has utilized Adjuster Assembly
Braking Systems - Hydraulic
frictional force to
help the applying force on both shoes.
If the brakes are applied while the vehicle is backing, the shoes
rotate in the direction of the drum rotation. This causes the
secondary shoe to leave the anchor and causes the primary shoe
to move against the anchor. Action of the brake is the same in
reverse as forward.
Uni-Servo
This type of hydraulic brake utilizes a single acting cylinder. Upon
actuation, the primary shoe is pressed against the brake drum,
which causes the shoe to move in the direction of rotation. This
movement in turn actuates the secondary shoe through the
adjuster assembly. Braking in reverse is significantly less effective
than in the forward direction.
-24-
Another variation is called a “free backing” brake which is
-25-
mounts to a support plate which is attached to the brake mounting
flange. The cable end is routed through the dust shield and the
brake spider, to attach to the internal parking brake lever. For 12¹⁄₄"
brakes produced after February of 2002, a short cable is installed
directly into the backing plate to provide a convenient means for
the trailer manufacturer to attach an appropriate operating system.
The internal parking brake lever of 10" and 12" Dexter brakes,
which is mounted to the secondary shoe, transfers applied cable
force through a parking strut which is attached to the primary
shoe. This transferred load generates a spreading force between
the primary and secondary shoes. The shoes move toward the
drum until contact is made. Friction generated between the drum
and lining contact surface results in parking brake capability.
The internal parking brake lever of Dexter 12¹⁄₄" brakes transfers
the applied cable force through a cam mechanism. The cam
mechanism generates a spreading force between the primary and
secondary shoes. The shoes move toward the drum until contact
is made. Friction generated between the drum and lining contact
surface results in parking brake capability.
Park Lever
Braking Systems - Hydraulic
Park Cable
-26-
Hydraulic Disc Brakes
-27-
Actuation Systems
To effectively operate your hydraulic trailer brakes we recommend
the Dexter electrically controlled hydraulic brake actuation device
(also referred to as E/H brake actuator), controlled by the Predator
DX2® electronic brake controller. These high performance
hydraulic power modules will supply pressurized brake fluid to
your trailer brakes in proportion to the amount of braking effort
called for by the towing vehicles’ deceleration rate.
CAUTION
It is the responsibility of the end user to ensure that
their in-cab electronic controller is compatible with the
Dexter E/H brake actuator. Dexter attempts to provide
compatibility with most controllers available, but is
unable to anticipate design changes that might be
introduced by the various controller manufacturers.
The E/H 1000 will supply 1,000 psi for your drum brakes and the
E/H 1600 will generate 1,600 psi for maximum output for your
Dexter disc brakes. The sealed, weather tight housing contains the
electronics necessary to control the high pressure piston pump
and proportioning valve for smooth, efficient braking.
Braking Systems - Hydraulic
Electrical Schematic
From Tow Trailer
Vehicle Controller Plug
(Typically Blue)
Blue
Black
+12 Volt 40 Amp White
Circuit From
Tow Vehicle
Ground From
Tow Vehicle Lanyard
BLACK
WHITE
Break-
Light Blue/Yellow
Away
Blue
Switch
Black
White
Orange/Black Hydraulic
Line
Charger
Yellow
Minimum
9 Amp Hour Connect
Breakaway To The
Battery Note: Either an onboard or breakaway
Trailer
Ground battery may be used.
Circuit
-28-
Braking Systems - Hydraulic
Scan to view
E/H Actuator Installation video
Troubleshooting Guide
Brakes are slow to respond
1. Re-bleed the trailer brakes and actuator.
2. If the trailer is equipped with drum brakes, readjust the drum
brakes to the brake manufacture’s recommended running
clearance.
3. Slow response can be caused by trailer wiring that is too
small.
4. For trailers where the E/H brake actuator is located
less than 10 feet from the tow vehicle, 12 gage wire is
recommended for the black and white wires between the
tow vehicle and the E/H brake actuator. All other wires
should be a minimum of 16 gauge.
5. For trailers where the E/H brake actuator is located
more than 10 feet from the tow vehicle, 10 gage wire is
recommended for the black and white wires between the
tow vehicle and the E/H brake actuator. All other wires
should be a minimum of 16 gauge.
6. Slow response can be caused by improper adjustment
of the brake controller. On inertia-based electronic brake
controls, adjust the pendulum (inertia sensor) to a more
aggressive setting and/or increase the gain setting.
Unit will not run when the ignition is on and the brake pedal
is depressed
1. Verify that the trailer and tow vehicle are wired as detailed
on the electrical schematic.
2. With the ignition switch on and the brakes not applied, you
should have 12-13 volts between the black and white wires
on the E/H brake actuator.
-29-
3. Clean and replace the ground between the trailer and the
E/H brake actuator.
4. Test operation of the unit using the breakaway test
procedure.
Breakaway test procedure - do not leave the breakaway
switch pulled for more than two minutes during any of the
steps outlined below
1. Pull the breakaway switch on the trailer.
2. If the unit runs and builds pressure, that indicates the
actuator is functioning properly. The problem most likely is
a defective electronic brake controller in the tow vehicle or
defective wiring between the tow vehicle and the E/H brake
actuator.
3. If the unit runs but will not build pressure, the problem most
likely is a defective solenoid valve in the E/H brake actuator
and the actuator should be replaced.
4. If the unit still does not run after the breakaway battery is
fully charged, verify that the voltage between the white wire
and yellow wire is at least 12 volts.
5. If the voltage is less than 12 volts, either the breakaway
switch or the breakaway wiring is defective.
Braking Systems - Hydraulic
-30-
General Maintenance ‑ Hydraulic Brakes
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
-31-
Most of the brake components are very similar to those used in
electric brakes, and maintenance is comparable for the hub and
drum, shoes and linings, and bearings. Specific maintenance
activities are as follows:
Wheel Cylinders
Inspect for leaks and smooth operation. Clean with brake cleaner
and flush with fresh brake fluid. Hone or replace as necessary.
Brake Lines
Check for cracks, kinks, or blockage. Flush with fresh brake fluid.
Bleed system to remove all air. Replace as necessary.
! CAUTION
POTENTIAL ASBESTOS DUST HAZARD!
Some older brake linings may contain asbestos dust,
which has been linked to serious or fatal illnesses.
Certain precautions need to be taken when servicing
brakes:
1. Avoid creating or breathing dust.
2. Avoid machining, filing or grinding the brake linings.
3. Do not use compressed air or dry brushing for
cleaning (dust can be removed with a damp brush).
-32-
of 40 m.p.h., slowing the vehicle to 20 m.p.h. Allow ample time for
Hardware
Check all hardware. Check shoe return spring, hold down springs,
and adjuster springs for stretch or wear. Replace as required.
Service kits are available.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can fall
unexpectedly and cause serious injury or death.
2. Remove the wheel from the hub, leaving the brake exposed.
3. Disable the brake actuation system. Check that the hydraulic
system has zero pressure and that the hub and rotor rotate
freely.
4. Remove the hose from the caliper, then remove the two
caliper mounting bolts. Do not allow the caliper to hang from
the hose.
-33-
Installing the new brake caliper
1. First, inspect the brake assembly for grooves, flaking,
cracks, heat checking, thickness variation, insufficient rotor
thickness, and look to see that the mounting hardware is
straight. Replace any component as needed (or desired) per
manufacturer recommendations.
2. Install the new caliper assembly. Make sure that the bleed
screw points up.
3. Remount the caliper assembly onto the caliper attaching
bracket. Ensure that there is thread locking compound on
the threads of the new mounting bolts. Torque mounting
bolts to 40-50 Ft. Lbs.
Note: Use two lug nuts to secure rotor against the hub
face when reassembling the caliper. After the caliper is
assembled remove the lug nuts.
4. Reconnect the hose to the elbow adapter on the back of the
caliper and torque to 10-12 Ft. Lbs.
5. Reconnect the brake actuation system. Refer to your
actuation systems Operation Maintenance Service Manual
for proper operation.
6. Bleed and flush brake system per your actuation systems
Braking Systems - Hydraulic
-34-
Braking Systems - Hydraulic
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can fall
unexpectedly and cause serious injury or death.
2. Remove the wheel from the hub, leaving the brake exposed.
3. Disable the brake actuation system. Check that the hydraulic
system has zero pressure and that the hub and rotor rotates
freely.
4. Remove the two caliper mounting bolts. Do not allow the
caliper assembly to hang from the hose. Do not disconnect
the hose or allow air into the hydraulic system.
5. With the caliper assembly out of the way remove the brake
rotor. Save the brake mounting hardware for reinstalling the
brake calipers.
Installing the new brake rotor
1. First inspect the brake assembly for grooves, flaking,
cracks, heat checking, thickness variation, insufficient rotor
thickness, and look to see that the mounting hardware is
straight. Replace any component as needed (or desired) per
manufacturer recommendations.
2. Install the new brake rotor by fitting it onto the hub flush with
the hub face.
3. Remount the caliper assembly onto the caliper attaching
bracket. Place thread locking compound on threads of
mounting bolts. Torque mounting bolts to 40-50 Ft. Lbs.
Note: Use two lug nuts to secure rotor against the hub
face when reassembling the calipers. After the calipers are
assembled remove the lug nuts.
4. Reconnect the brake actuation system. Refer to your
Operation Maintenance Service Manual for proper
operation.
-35-
5. Remount the wheel. Refer to your Operation Maintenance
Service Manual for proper wheel nut torque procedures.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can fall
unexpectedly and cause serious injury or death.
2. Remove the wheel from the hub, leaving the brake exposed.
Braking Systems - Hydraulic
-36-
Installing the new brake rotor
-37-
Remove the old brake rotor
1. Jack up trailer and secure on adequate capacity jack stands.
Follow trailer manufacturers recommendations for lifting and
supporting the unit.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can fall
unexpectedly and cause serious injury or death.
2. Remove the wheel from the hub, leaving the brake exposed.
3. Disable the brake actuation system. Check that the hydraulic
system has zero pressure and that the hub/rotor rotates
freely.
4. For brakes produced after April 2008, locate the crossover
brake line threaded into the bottom side of both calipers.
The crossover brake line is attached to the inboard side of
the anchor yoke using a metal tube clamp. Remove the
¹⁄₄-20 bolt that connects the tube clamp to the yoke.
Braking Systems - Hydraulic
-38-
3. Install washer and spindle nut onto spindle to secure hub.
-39-
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can fall
unexpectedly and cause serious injury or death.
2. Remove the wheel from the hub, leaving the brake exposed.
3. Disconnect the brake actuation system. Check that the
hydraulic system has zero pressure and that the hub and
rotor rotates freely.
4. Remove the brake pad retaining pin.
5. Remove the old pads from the caliper assembly. Save the
brake pad retaining hardware for reinstalling the new pads
onto the caliper.
! CAUTION
POTENTIAL ASBESTOS DUST HAZARD!
Some older brake linings may contain asbestos dust,
Braking Systems - Hydraulic
-40-
Note: Use two lug nuts to secure rotor against the hub
Figure 1
-41-
Instructions for Brake Caliper Kit
6K, 7K or 8K Hydraulic Disc Brakes
Notice to Buyer
It is recommended that all brakes be replaced at the same time to
ensure balanced braking performance.
Remove the old brake calipers
1. Jack up trailer and secure on adequate capacity jack stands.
Follow trailer manufacturers recommendations for lifting and
supporting the unit.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can fall
unexpectedly and cause serious injury or death.
2. Remove the wheel from the hub, leaving the brake exposed.
3. Disable the brake actuation system. Check that the hydraulic
system has zero pressure and that the hub and rotor rotates
Braking Systems - Hydraulic
freely.
4. For brakes produced after April 2008, the crossover brake
line also attaches to the inboard side of the caliper mounting
bracket using the metal tube clamp. Slide the clamp over
the crossover brake line and bend it to the closed position.
Apply anti-seize or similar thread lubricant to the ¹⁄₄-20,
¹⁄₂" bolt. Attach the tube clamp to the threaded hole in the
caliper mounting bracket using the ¹⁄₄-20, ¹⁄₂" length bolt.
Torque to 85-100 In. Lbs.
5. Remove the hose from the caliper, then remove the four
caliper mounting bolts. Do not allow the caliper to hang from
the hose.
Installing the new brake caliper
1. First inspect the brake assembly for grooves, flaking,
cracks, heat checking, thickness variation, insufficient rotor
-42-
thickness, and look to see that the mounting hardware is
-43-
second pin out of the inboard caliper half. Install cotter ring.
7. Reconnect the brake actuation system. Refer to your
Operation Maintenance Service Manual for proper
operation.
8. Bleed and flush brake system per your actuation systems
Operation Maintenance Service Manual.
9. Remount the wheel. Refer to your Operation Maintenance
Service Manual for proper wheel nut torque procedures.
10. Spin wheel to ensure proper clearance between the wheel,
crossover brake line, and the rotor.
Braking Systems - Hydraulic
-44-
Introduction to Troubleshooting
CAUTION
The maximum operating pressure for Dexter brakes:
• 7" diameter drum brakes
maximum operating pressure is 750 psi
• 10" diameter and larger drum brakes
maximum operating pressure is 1,000 psi
• Hydraulic disc brakes (all sizes)
maximum operating pressure is 1,600 psi
-45-
Troubleshooting
SYMPTOM CAUSES REMEDIES
Broken or Kinked Repair or Replace
Brake Line
No Brakes Severe
Underadjustment Adjust Brakes
Malfunctioning Troubleshoot
Actuating System System
-46-
Troubleshooting
Underadjustment Adjust
One Side
Out-of-Adjustment Adjust
-47-
Hubs/Drums/Bearings
Dexter offers several types of bearing arrangements and
lubrication methods.
• Dexter’s standard wheel bearing configuration consists of
opposed tapered roller bearing cones and cups, fitted inside
of a precision machined cast hub. This method of using
tapered roller bearings requires that a minimal amount of
axial end play be provided at assembly. This end play is
essential to the longevity of the bearings service life. This
design is typically lubricated with grease, packed into the
bearings. Oil lubrication is another method which is available
in some of the larger axle capacities.
• E-Z Lube® is another option chosen by some trailer
manufacturers. If your axle is equipped with the Dexter
E‑Z Lube® feature, the bearings can be periodically
lubricated without removing the hubs from the axle. This
feature consists of axle spindles that have been specially
drilled and assembled with grease fittings in their ends.
When grease is pumped into the fitting, it is channeled to
the inner bearing and then flows back to the outer bearing
and eventually back out the grease cap hole.
• Nev-R-Lube® option is the latest innovation from Dexter.
Nev-R-Lube® bearings are comprised of opposed tapered
roller bearing cones sealed inside of a precision ground,
one piece double cup arrangement. These bearings are
Hubs/Drums/Bearings
Scan to view
Bearing Maintenance video
-48-
Hub Removal - Standard Bearings
Hubs/Drums/Bearings
Whenever the hub equipment on your axle must be removed for
inspection or maintenance the following procedure should be
utilized.
1. Elevate and support the trailer unit per manufacturers’
instructions.
! CAUTION
You must follow the maintenance procedures to prevent
damage to important structural components. Damage to
certain structural components such as wheel bearings
can cause the wheel end to come off of the axle. Loss of
a wheel end while the trailer is moving can cause you to
lose control and lead to an accident, which can result in
serious injury or death.
-49-
the armature surface where the magnet contacts (only in electric
brakes).
The drum surface should be inspected for excessive wear or
heavy scoring. If worn more than .020" oversized, or the drum
has worn out of round by more than .015", then the drum surface
should be re-machined. If scoring or other wear is greater than
.090” on the diameter, the drum must be replaced. When turning
the drum surface, the maximum rebore diameter is as follows:
• 7" Brake Drum-7.090" diameter
• 10" Brake Drum-10.090" diameter
• 12" Brake Drum-12.090" diameter
• 12¹⁄₄" Brake Drum-12.340" diameter
• 6K, 7K and 8K Rotor-1.03" minimum thickness
• 3.5K Rotor-.85" minimum thickness
The machined inner surface of the brake drum that contacts the
brake magnet is called the armature surface. If the armature
surface is scored or worn unevenly, it should be refaced to a 120
micro inch finish by removing not more than .030" of material. To
ensure proper contact between the armature face and the magnet
face, the magnets should be replaced whenever the armature
surface is refaced and the armature surface should be refaced
whenever the magnets are replaced.
Note: It is important to protect the wheel bearing bores from
metallic chips and contamination which result from drum turning or
armature refacing operations. Make certain that the wheel bearing
cavities are clean and free of contamination before reinstalling
Hubs/Drums/Bearings
Bearing Inspection
Wash all grease and oil from the bearing cone using a suitable
solvent. Dry the bearing with a clean, lint-free cloth and inspect
each roller completely.
CAUTION
Never spin the bearing with compressed air.
THIS CAN DAMAGE THE BEARING.
-50-
If any pitting, spalling, or corrosion is present, then the bearing
Hubs/Drums/Bearings
must be replaced. The bearing cup inside the hub must be
inspected.
IMPORTANT: Bearings must always be replaced in sets of a cone
and a cup.
! CAUTION
Be sure to wear safety glasses when removing or
installing force fitted parts. Failure to comply may result
in serious eye injury.
-51-
Bearing Lubrication - Grease
CAUTION
Do not mix Lithium, calcium, sodium or barium complex
greases due to possible compatibility problems.
When changing from one type of grease to another,
it is necessary to ensure all the old grease has been
removed.
-52-
Recommended Wheel Bearing
Hubs/Drums/Bearings
Lubrication Specifications
Grease
Thickener Type Lithium Complex
Dropping Point 215°C (419°F) Minimum
Consistency NLGI No. 2
Additives EP, Corrosion & Oxidation Inhibitors
Viscosity Index 80 Minimum
-53-
Oil
SAE 90, SAE 80W-90, SAE 75W-90
Approved Oil Sources
Ashland Oil Valvoline DuraBlend
CITGO Petroleum Co. CITGO Premium Gear Oil MP
Mystik JT-7
Mystik Power Lube
Conoco Universal Gear Lubricant 80W-90
Exxon Company USA Gear Oil GX 80W-90
Industrial Oils Unlimited Super MP Gear Oil 80W-90
Kendall Refining Co. Kendall NS-MP Hypoid Gear Lube
Lubriplate Division/ Lubriplate APG 90
Fiske Brothers Refining
MFA Oil Company Multi-Purpose Gear Oil 80W-90
Mobil Oil Corporation Mobilube SHC
Mobil 1 Synthetic Gear Lube
Phillips 66 Petroleum Superior Multi-Purpose Gear Oil
Philguard Gear Oil
Philsyn Gear Oil
Pennzoil Products Co. Gear Plus 80W-90 GL-5
Gear Plus Super 75W-90
Gear Plus Super EW 80W-90
Multi-Purpose 4092 Gear Lube
Oil Center Research Liquid-O-Ring 750 GX
Hubs/Drums/Bearings
-54-
Note: The convenient lubrication provisions of the E‑Z Lube®
Hubs/Drums/Bearings
and the oil lubrication must not replace periodic inspection of the
bearings.
-55-
5. Orient the seal properly. Many oil bath seals will be marked
AIR SIDE on the side of the seal to facing out of the hub
after installation.
6. Install new seal into place using a seal driver or seal
installation tool of proper size. It is important that any seal
installation tool contact the outer ring of the seal casing. If
no seal driver is available, use a clean block of wood. It is
critical that the seal be driven in evenly and straight. NEVER
hammer directly on the seal.
7. The seals will be pressed flush to the back surface of the
hub in the 600-8,000 lbs. capacity product line. It is NEVER
necessary to bottom out the seal for proper installation.
Driving the seal in too deep may damage the seal and may
come in contact with the inner bearing preventing it from
rotating freely.
8. Proper installation will maintain the seal flatness in the hub
within .010". A seal that is cocked too much inside the hub
will be more likely to leak.
-56-
For E-Z Lube® axles using the new nut retainer:
Hubs/Drums/Bearings
1. After placing the hub, bearings, washers, and spindle nut
back on the axle spindle in reverse order as detailed in the
previous section on hub removal, rotate the hub assembly
slowly while tightening the spindle nut to approximately
50 Ft. Lbs. (12" wrench or pliers with full hand force.)
2. Then loosen the spindle nut to remove the torque. Do not
rotate the hub.
3. Finger tighten the nut until just snug, align the retainer to the
machined flat on the spindle and press the retainer onto the
nut. The retainer should snap into place. Once in place, the
retainer/nut assembly should be free to move slightly.
4. If the nut is too tight, remove the retainer and back the nut
off approximately one twelfth of a turn and reinstall the
retainer. The nut should now be free to move slightly.
5. Reinstall grease cap.
Nut
-57-
4. When the new clean grease is observed, remove the grease
gun, wipe off any excess, and replace the rubber plug in the
cap.
5. Rotate hub or drum while adding grease.
Note: The E-Z Lube® feature is designed to allow immersion
in water. Axles not equipped with E-Z Lube® are not
designed for immersion and bearings should be repacked
after each immersion. If hubs are removed from an axle
with the E-Z Lube® feature, it is imperative that the seals
be replaced BEFORE bearing lubrication. Otherwise,
the chance of grease getting on brake linings is greatly
increased.
Note: Dexter strongly recommends not using pneumatic
powered grease guns as these can inject grease too fast
and force grease past the seal, or in rare cases dislodge the
seal.
Inner Bearing
Rubber Plug
Outer Bearing
Grease
Flow
Grease Fitting
Hubs/Drums/Bearings
Spring Loaded
Metal End Cap Double Lip Seal
-58-
Nev-R-Lube® Drums/Bearings
Hubs/Drums/Bearings
Dexter’s Nev-R-Lube® bearings are comprised of opposed tapered
roller bearing cones sealed inside of a precision ground, one
piece double cup arrangement. These bearings are designed with
a small amount of axial end play. This end play is essential to the
longevity of the bearings service life.
CAUTION
Dexter has advised trailer manufacturers of certain
wheel limitations when used with the Nev-R-Lube®
bearings. The offset of the wheel must be as listed.
Deviation from these limits will result in limited bearing
life and possible catastrophic failure.
• 35MM - use only zero offset wheels
• 42MM - use only zero offset wheels
• 50MM - use only zero offset to .19" wheels
-59-
Drum Removal
Whenever the hub equipment on your axle must be removed for
inspection or maintenance, the following procedure should be
utilized.
1. Elevate and support the trailer unit per manufacturer’s
instructions.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
Bearing Inspection
Important:
1. Elevate and support the trailer unit per manufacturer’s
instructions.
-60-
Hubs/Drums/Bearings
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
-61-
Resultant Tilt
Bearing Size End Play Value
35 MM .005" axial .003" / per inch
42 MM .006" axial .005" / per inch
50 MM .008" axial .004" / per inch
-62-
damage the bearing and/or seals during installation. Press
Hubs/Drums/Bearings
bearing until it seats against the backup shoulder machined
into the hub.
5. Install “internal” snap ring into hub.
6. Clean and inspect spindle shaft. Apply a light coating of
anti‑seize lubricant to the spindle shaft prior to assembling
drum.
7. Install drum assembly onto spindle (Do Not Force).
8. Install steel washer onto spindle end.
9. Start self-locking nut onto spindle thread by hand. Complete
installation using a 1⁷⁄₁₆" 6 or 12 point socket and torque
wrench. Nut should be torqued to 145-155 Ft. Lbs. (this
torque will set the internal bearing adjustment, no other
adjustments are to be made).
10. Install “torque instruction” washer onto end of spindle.
11. Install “external” snap ring onto end of spindle to retain
washer.
12. Inspect assembly for excessive end play, noise, and rotation
restriction prior to mounting final wheel end hardware.
-63-
Axle & Suspension Installation
Responsibility for proper axle alignment lies with the axle installer.
The axle must be installed so that it will be parallel to the drive
axle(s) of the tractor. This will allow good vehicle control when
cornering, longer tire wear, and it will eliminate dog tracking.
Alignment can be determined by measuring from the center of
the trailer king pin to the center of each end of the axles. The
difference should not vary by more than ¹⁄₁₆". In the case of
multiple axles, the axles must also be in line with each other. The
difference between the centers of one axle and end centers of the
other axle must not vary more than ¹⁄₈".
! CAUTION
Safety glasses should be worn at all times when
assembling or disassembling axles and their
components.
Dexter tubular axles are made of high strength steel for better
fatigue life and superior welding qualities. The round tubular axles
provide a uniform section modulus no matter how the beam is
rotated.
Axle Installation
-64-
Suspension Systems
Suspensions
The suspension systems incorporated into Dexter axles are
designed to provide the trailer owner three basic functions:
1. Attach the axle to the trailer
2. Dampen the effects of road shock
3. Cushion the cargo or load
All Dexter suspension systems are available in single and multiple
axle configurations. The three types most commonly available are
double eye leaf spring, slipper spring, and Torflex®.
Center Hanger
Shackle Link
Front U-Bolt Rear
Hanger Hanger
Tie Plate
Shackle Bolts
Equalizer
Underslung Shown
-65-
Grease Lubricated Suspension Bushings
Dexter offers a variety of optional heavy duty attaching parts
kits for double eye leaf spring suspensions up to 8,000 lb. axle
capacity. The kits contain extra heavy shackle links, bronze
bushings for the spring eyes, and suspension bolts and equalizers
equipped with grease fittings to provide a convenient means
to lubricate all the pivot points including the rubber E-Z Flex®
equalizer center bushings. For availability, contact your nearest
Dexter facility or visit us online at www.dexteraxle.com for a
complete listing of genuine repair parts.
Overslung Shown
-66-
Inspection and Replacement
Suspensions
All the components of your suspension system should be visually
inspected at least every 6,000 miles for signs of excess wear,
elongation of bolt holes, and loosening of fasteners. Whenever
loose or replaced, the fasteners in your suspension system should
be torqued as detailed in the charts below. All wet bolts and
equalizers should be greased every 3,000 miles.
! CAUTION
You must follow the maintenance procedures to prevent
damage to important structural components. Damage to
certain structural components such as wheel bearings
can cause the wheel to come off of the axle. Loss of a
wheel end while the trailer is moving can cause you to
lose control and lead to an accident, which can result in
serious injury or death.
-67-
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
! CAUTION
Be sure to wear safety glasses when removing or
installing force fitted parts. Failure to comply may result
in serious injury.
6. Drive the new bushing into the spring eye using a piloted
drift punch or a close fitting bolt inserted through the
bushing.
7. Reinstall repaired or replaced components in reverse order.
Note: For multiple axle units, the weight of each axle must
be supported as outlined in Step 2 before disassembly of
Suspensions
-68-
1. With both axles blocked up, remove the spring eye bolt,
Suspensions
shackle bolt, and equalizer bolt from the equalizer to be
repaired or replaced.
2. Take the equalizer to suitable work surface and remove the
worn bushings using a suitable drift punch.
3. Drive the new bushings into place using a piloted drift punch
or a close fitting bolt through the bushing.
4. Reassemble in reverse order.
! CAUTION
Be sure to wear safety glasses when removing or
installing force fitted parts. Failure to comply may result
in serious injury.
Torflex® Suspension
The Torflex® suspension system is a torsion arm type suspension
which is completely self contained within the axle tube. It attaches
directly to the trailer frame
using brackets which Mounting Bracket Axle Tube
are an integral part of
the axle assembly. The
Torflex® axle provides
improved suspension Spindle
characteristics relative to
leaf spring axles through
the unique arrangement Torsion Bar
of a steel torsion bar Torsion Arm
surrounded by four
natural rubber cords
encased in the main structural member of the axle beam.
-69-
The wheel/hub spindle is attached to a lever, called the torsion
arm, which is fastened to the rubber encased bar. As load is
applied, the bar rotates causing a rolling/compressive resistance
in the rubber cords. This action provides the same functions as
conventional sprung axles with several operating advantages
including independent suspension.
Except for periodic inspection of the fasteners used to attach
the Torflex® axle to the vehicle frame, no other suspension
maintenance is required on Torflex® axles. They are, of course,
subject to the maintenance and inspection procedures regarding
brakes, hubs, bearings, seals, wheels, and tires as outlined in this
manual.
CAUTION
DO NOT WELD ON THE TORFLEX® BEAM. It has rubber
cords inside and the heat generated by welding could
damage the cords.
Airflex® Suspension
The Dexter Airflex® suspension is a unique combination of
Torflex® axle and conventional air suspension technology. This low
maintenance suspension system carries the load on a cushion of
air, usually supplied by an on-board compressor and storage tank.
A load leveling valve maintains a constant ride height, regardless
of load. As load is added to the trailer, the valve will automatically
signal the compressor to supply more air. As loads are removed,
the same valve will exhaust air to maintain the same height and
ride characteristics.
The Airflex® suspension air generation kit has a built in dump valve
which allows the trailer to be lowered several inches to facilitate
Suspensions
-70-
Note: Lifting the trailer with air system pressurized will
Suspensions
overextend the air bags and can result in damage to the air
bags.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
-71-
Wheels
Wheel Selection
Wheels are a very important and critical component of your
running gear system. When specifying or replacing your trailer
wheels it is important that the wheels, tires, and axle are properly
matched. The following characteristics are extremely important
and should be thoroughly checked when replacement wheels are
considered.
1. Bolt Circle. Many bolt circle dimensions are available.
Some vary by so little that it might be possible to attach an
improper wheel that does not match the axle hub. Be sure to
match your wheel to the axle hub.
2. Capacity. Make sure that the wheels have enough
load carrying capacity and pressure rating to match the
maximum load of the tire and trailer.
3. Offset. This refers to the relationship of the center line of
the tire to the hub face of the axle. Care should be taken to
match any replacement wheel with the same offset wheel
as originally equipped. Failure to match offset can result in
reducing the load carrying capacity of your axle.
4. Rim Contour.
! CAUTION
Replacement tires must meet the same specifications
as the originals. Mismatched tires and rims may come
Wheels and Tires
-72-
Wheels and Tires
! CAUTION
Do not attempt to repair or modify a damaged wheel.
Even minor modifications can cause a dangerous failure
of the wheel and result in personal injury or death.
Torque Requirements
In June of 2004, Dexter ceased production of trailer wheels. If your
vehicle is equipped with Dexter steel wheels manufactured before
that date, the following wheel torque information will be applicable.
If your trailer is equipped with wheels produced by other
manufacturers, you must consult with the vehicle manufacturer to
determine the appropriate torque level for your wheels. However,
you must not exceed the limits of the wheel mounting studs on the
axles.
It is extremely important to apply and maintain proper wheel
mounting torque on your trailer axle. Torque is a measure of the
amount of tightening applied to a fastener (nut or bolt) and is
expressed as length force. For example, a force of 90 pounds
applied at the end of a wrench one foot long will yield 90 Ft. Lbs.
of torque. Torque wrenches are the best method to assure the
proper amount of torque is being applied to a fastener.
! CAUTION
Wheel nuts or bolts must be tightened and maintained
at the proper torque levels to prevent loose wheels,
broken studs, and possible dangerous separation of
wheels from your axle, which can lead to an accident,
personal injuries or death.
-73-
2. Tighten bolts or nuts in the sequence shown for Wheel
Torque Requirements.
3. The tightening of the fasteners should be done in stages.
Following the recommended sequence, tighten fasteners
per wheel torque requirements diagram.
4. Wheel nuts/bolts should be torqued before first road use
and after each wheel removal. Check and re-torque after
the first 10 miles, 25 miles, and again at 50 miles. Check
periodically thereafter.
Cone Nuts
17.5" Hub Pilot ⁵⁄₈"-18 50-60 100-120 190-210 Hub Piloted
865 BC With Clamp
Ring. 90° Cone
Nuts & Greased
Threads
17.5" Hub Pilot ⁵⁄₈"-18 50-60 90-200 275-325 Hub Piloted With
865 BC Flange Nut
17.5" Hub Pilot ⁵⁄₈"-18 50-60 60-110 150-175 Hub Piloted With
865 BC Swivel Flange
Nut
-74-
TORQUE SEQUENCE
4 5
2 5 4 5
2 2 2
4 BOLT 5 BOLT 6 BOLT 8 BOLT
! CAUTION
Exceeding the above listed torque limits can damage
studs and/or nuts and lead to eventual fractures and
dangerous wheel separation.
CAUTION
Dexter’s patented Torq-N-Go™ swiveling wheel nut
generates significantly more clamp load than standard
wheel nuts. Do not exceed the specified torque or the
wheel and/or stud may be damaged. Special caution
should be observed with steel wheels. Some steel center
discs may not be able to withstand the Torq-N-Go™ wheel
nuts’ specified operating torque. It is the responsibility
of the trailer manufacturer to assure that its’ wheels are
compatible with this wheel nut.
-75-
Tires
Before mounting tires onto the wheels, make certain that the rim
size and contour is approved for the tire as shown in the Tire and
Rim Association Yearbook or the tire manufacturers catalog. Also
make sure the tire will carry the rated load. If the load is not equal
on all tires due to trailer weight distribution, use the tire rated for
the heaviest wheel position.
Note: The capacity rating molded into the sidewall of the tire is not
always the proper rating for the tire if used in a trailer application.
Use the following guidelines:
1. LT and ST tires. Use the capacity rating molded into the tire.
2. Passenger Car Tires. Use the capacity rating molded into
the tire sidewall divided by 1.10 for trailer use.
Use tire mounting procedures as outlined by the Rubber
Manufacturer’s Association or the tire manufacturers.
Tire inflation pressure is the most important factor in tire life.
Inflation pressure should be as recommended by the manufacturer
for the load. Pressure should be checked cold before operation.
Do not bleed air from tires when they are hot. Check inflation
pressure weekly during use to ensure the maximum tire life and
tread wear. The following tire wear diagnostic chart will help you
pinpoint the causes and solutions of tire wear problems.
CAUTION
Proper matching of the tire/wheel combination is
essential to proper function of your trailer running gear.
Wheels and Tires
-76-
Tire Wear Diagnostic Chart
Align at alignment
Toe Wear Incorrect toe-in
shop
Check bearing
Cupping Out-of-balance adjustment and
balance tires
Avoid sudden stops
Wheel lockup
Flat Spots when possible and
& tire skidding
adjust brakes
CAUTION
Tire wear should be checked frequently. Once a wear
pattern becomes firmly established in a tire it is difficult
to stop, even if the underlying cause is corrected.
-77-
Replacement Parts/Kits
Electric Brake Magnets
Nut Torque
Magnet Kit Number Wire (Ft. Lbs.)
Brake Size (one magnet per kit) Color Brake Mounting
7" x 1¹⁄₄" K71-057-00 White 45-70
10" x 1¹⁄₂" K71-104-00 Green 45-70
10" x 2¹⁄₄" K71-104-00 Green 45-70
10" x 2¹⁄₄" K71-125-00 (4.4K) Black 45-70
12" x 2" K71-105-00 White 25-50
12" x 2" K71-125-00 (7K) Black 25-50
12¹⁄₄" x 2¹⁄₂" K71-378-00 Red/Black 55-80
12¹⁄₄" x 3³⁄₈" K71-378-00 Red/Black 55-80
-78-
Brake Shoe Replacement Kits
Replacement Parts/Kits
Shoe and Lining Replacement (1 Brake)
Brake Size Electric Hydraulic
7" x 1¹⁄₄" (2.2K) K71-045-00 N/A
7" x 1³⁄₄" (2.5K) N/A K71-466-00
10" x 1¹⁄₂" (3.0K) K71-046-00 N/A
Nev-R-Adjust® (3.0K) K71-701-00LH K71-702-00RH N/A
10" x 2¹⁄₄" (3.5K) K71-047-00 K71-267-00
Nev-R-Adjust® (3.5K) K71-681-00LH K71-682-00RH N/A
Free Backing (3.5K) N/A K71-393-00
Corrosion Resistant (3.5K) N/A K71-423-00
4.4K K71-672-00 N/A
Nev-R-Adjust® (4.4K) K71-698-00LH K71-699-00RH N/A
12" x 2" (5.2K) K71-127-00 K71-268-00
6K K71-127-00 N/A
Nev-R-Adjust® (6 & 7K) K71-675-00LH K71-676-00RH N/A
7K K71-127-00 K71-269-00LH K71-270-00RH
Free Backing (7K) N/A K71-394-00LH K71-395-00RH
Corrosion Resistant (7K) N/A K71-427-00LH K71-428-00RH
12¹⁄₄" x 2¹⁄₂" (7.2K) K71-497-00LH K71-496-00RH N/A
(after May of 2000)
Service Parts Only (7.2K) K71-410-00 N/A
(before May of 2000)
12¹⁄₄" x 3³⁄₈" (8K) K71-499-00LH K71-498-00RH K71-165-00LH K71-166-00RH
Corrosion Resistant (8K) N/A K71-437-00LH K71-438-00RH
12¹⁄₄" x 3³⁄₈" (8K) K71-049-00LH K71-050-00RH K71-165-00LH K71-166-00RH
(stamped backing plate
before April 2000)
3.5K Disc N/A K71-623-00 (1 axle set)
6.0K Disc N/A K71-629-00 (1 axle set)
7.0K Disc N/A K71-629-00 (1 axle set)
8.0K Disc N/A K71-629-00 (1 axle set)
-79-
Bearing Replacement Chart
Brake Hub Dexter Kit Industry Part # Axle
Size Size Bearings Number Cup/Cone Capacity
7" x 1¹⁄₄" 4 or 5 Inner K71-306-00 L44610/L44649 2K
Bolt Outer K71-306-00 L44610/L44649
10" x 1¹⁄₂" 4 or 5 Inner K71-307-00 LM67010/LM67048 2.8K
Bolt Outer K71-306-00 L44610/L44649
10" x 1¹⁄₂" 5 Bolt Inner K71-307-00 LM67010/LM67048 3K
Outer K71-306-00 L44610/L44649
10" x 2¹⁄₄" 4, 5, or 6 Inner K71-390-00 L68111/L68149 3.5K
Bolt Outer K71-306-00 L44610/L44649 4K (10F)
10" x 2¹⁄₄" 6 Bolt Inner K71-390-00 L68111/L68149 4.4K
Outer K71-307-00 LM67010/LM67048
12" x 2" 6 Bolt Inner K71-308-00 25520/25580 5.2K
Outer K71-307-00 LM67010/LM67048
12" x 2" 5 Bolt Inner K71-308-00 25520/25580 7K
Demount Outer K71-309-00 15245/15123
12" x 2"* 6 Bolt Inner K71-308-00 25520/25580 6K
Outer K71-309-00 15245/15123
12" x 2" 8 Bolt Inner K71-308-00 25520/25580 6K, 7K
Outer K71-310-00 14276/14125A
12¹⁄₄" x 2¹⁄₂" 8 Bolt Inner K71-308-00 25520/25580 7.2K
Outer K71-405-00 02420/02475
12¹⁄₄" x 3³⁄₈" 8 Bolt Inner K71-308-00 25520/25580 8K
Outer K71-415-00 02420/02475
Replacement Parts/Kits
-80-
Storage
Storage
Storage Preparation
If your trailer is to be stored for an extended period of time or over
the winter, it is important that the trailer be prepared properly.
1. Remove the emergency breakaway battery and store inside,
out of the weather. Charge the battery at least every 90
days.
2. Jack up the trailer and place jack stands under the trailer
frame so that the weight will be off the tires. Follow trailer
manufacturer’s guidelines to lift and support the unit. Never
jack up or place jack stands on the axle tube or on the
equalizers.
! CAUTION
Do not lift or support the trailer on any part of the axle
or suspension system. Never go under any trailer unless
it is properly supported on jack stands which have been
rated for the load. Improperly supported vehicles can
fall unexpectedly and cause serious injury or death.
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After Prolonged Storage
Inspection Procedure
Before removing trailer from jack stands:
1. Remove all wheels and hubs or brake drums. Note which
spindle and brake that the drum was removed from so that it
can be reinstalled in the same location.
2. Inspect suspension for wear.
3. Check tightness of hanger bolt, shackle bolt, and U-bolt nuts
per recommended torque values.
4. Check brake linings, brake drums and armature faces for
excessive wear or scoring.
5. Check brake magnets with an ohmmeter. The magnets
should check 3.2 ohms. If shorted or worn excessively, they
must be replaced.
6. Lubricate all brake moving parts using a high temperature
brake lubricant (LUBRIPLATE or Equivalent).
CAUTION
Do not get grease or oil on brake linings or magnet face.
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Trip Preparation Checklist
Storage
There are a number of simple rules to follow in caring for your
trailer axle assembly that can add to its life and in the case of
some of these rules, you may be protecting your own life as well.
Using the following checklist before starting a trip with your trailer
is highly recommended. Some of these items should be checked
2-3 weeks prior to a planned trip to allow sufficient time to perform
maintenance.
1. Check your maintenance schedule and be sure you are
up‑to-date.
2. Check hitch. Is it showing wear? Is it properly lubricated?
3. Fasten safety chains and breakaway switch actuating
chain securely. Make certain the breakaway battery is fully
charged.
4. Inspect towing hookup for secure attachment.
5. Load your trailer so that approximately 10% of the trailers
total weight is on the hitch. For light trailers this should be
increased to 15%.
6. Do Not Overload. Stay within your gross vehicle rated
capacity (consult your trailers identification plate).
7. Inflate tires according to manufacturer’s specifications;
inspect tires for cuts, excessive wear, etc.
8. Check wheel mounting nuts/bolts with a torque wrench.
Torque in proper sequence, to the levels specified in this
manual.
9. Make certain the brakes are synchronized and functioning
properly.
10. Check tightness of hanger bolt, shackle bolt, and U-bolt nuts
per torque values specified in manual.
11. Check operation of all lights.
12. Check that your trailer is towing in a level position and adjust
hitch height if required.
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Maintenance Schedule
3 Months or 6 Months or 12 Months or
Item Function Required Weekly 3,000 Miles 6,000 Miles 12,000 Miles
Hub/Drum
Inspect for abnormal wear
or scoring. •
Wheel Bearings
and Cups
Inspect for corrosion or
wear. Clean and repack. •
Seals
Inspect for leakage.
Replace if removed. •
Springs
Inspect for wear, loss of
arch. •
Inspect for bending, loose
•
Maintenance Schedule
Suspension Parts
fasteners and wear.
Suspension Wet
Bolts & Equalizers
Grease.
•
Extreme Duty
Bushings
Grease.
•
Hangers Inspect welds.
•
Wheel Nuts
and Bolts
Tighten to specified torque
values. •
Wheels
Inspect for cracks, dents, or
distortion. •
Tire Inflation
Pressure
Inflate tires to mfg’s.
specifications. •
Tire Condition
Inspect for cuts, wear,
bulging, etc. •
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Dexter Axle Limited Warranty
Warranty
What Products Are Covered
All Dexter Axle Company (“Dexter”) trailer axles, suspensions,
and brake control systems manufactured on or after September 1,
2016, excluding Dexter 6000 series Manufactured Housing Axles.
Additional exclusions include the following brands: UFP by Dexter,
AL-KO (IAC), Titan Brakes and Actuators by Dexter, and BrakeRite
by Dexter products, which are covered under separate warranties.
Limited 1 Year Warranty
As specified in Dexter’s current publication “Operation
Maintenance Service Manual”, grease and oil seals FOR ALL
PRODUCTS have a one (1) year limited warranty to the original
purchaser from the date of first sale of the trailer incorporating
such components. Except as to grease and oil seals, the
following four other warranties are available.
Limited 2 Year Warranty
Dexter warrants to the original purchaser that its electric/hydraulic
brake actuators shall be free from defects in material and
workmanship for a period of two (2) years from the date of first
sale of the trailer incorporating such components.
Limited 5 Year Warranty
Dexter warrants to the original purchaser that its axles,
suspension systems and Genuine Replacement Parts shall be
free from defects in material and workmanship for a period of five
(5) years. The warranty period shall begin from the date of the
original purchase of the trailer and/or Genuine Replacement Parts.
Limited 7 Year Warranty
Dexter warrants to the original purchaser that its Predator Series®
electric brake controllers shall be free from defects in material
and workmanship for a period of seven (7) years from the date of
purchase.
Limited 10 Year Warranty
Dexter warrants to the original purchaser that the suspension
components of its Torflex® axles shall be free from defects in
material and workmanship for a period of ten (10) years from
the date of first sale of the trailer incorporating such suspension
components.
Exclusive Remedy
Dexter will, at its option, repair or replace the affected components
of any defective axle, repair or replace the entire defective
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axle, or refund the lesser of the original purchase price and the
then-current list price of the axle or components. In all cases, a
reasonable time period must be allowed for warranty repairs to
be completed. Allowance will only be made for installation costs
specifically approved by Dexter.
What You Must Do
In order to make a claim under these warranties:
1. You must be the original purchaser of the trailer in which the
sprung suspension axles or Torflex® axles or components were
originally installed.
2. You must promptly notify Dexter after detection of any defect,
but in any case within the applicable warranty period of such
defect, and provide us with the axle or applicable component
serial number and any substantiation of such defect which may
include, but is not limited to, the return of part(s) that we may
reasonable request.
3. The axles, suspensions and components must have been
installed and maintained in accordance with good industry
practice and any specific Dexter recommendations, including
those specified in Dexter’s current publication “Operation
Maintenance Service Manual”.
Exclusions
These warranties do not extend to and do not cover defects
caused by:
1. The connecting of brake wiring to the trailer wiring or trailer
wiring to the towing vehicle wiring.
2. The attachment of the running gear to the frame.
3. Parts not supplied by Dexter.
4. Any damage whatsoever caused by or related to any alteration
of the axle including welding supplemental brackets to the axle.
5. Use of an axle on a unit other than the unit to which it was
originally mounted.
6. Normal wear and tear.
7. Improper alignment.
Warranty
8. Improper installation.
9. Unreasonable use (including failure to provide reasonable
and necessary maintenance as specified in Dexter’s current
publication “Operation Maintenance Service Manual including
required maintenance after “Prolonged Storage”).
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10. Improper torque values and torqueing of wheel nuts. (The
Warranty
proper torqueing procedure and torque values are contained
in Dexter’s current publication “Operation Maintenance Service
Manual”).
11. Cosmetic finish or corrosion.
Limitations
1. In all cases, Dexter reserves the right to fully satisfy its
obligations under the Limited Warranties by refunding
the lesser of the original purchase price and the then-
current list price of the defective axle (or, if the axle has
been discontinued, of the most nearly comparable current
product).
2. Dexter reserves the right to furnish a substitute of replacement
component or product in the event an axle or any component
of the axle is discontinued or is otherwise unavailable.
3. These warranties are nontransferable.
General
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN
LIEU OF ALL OTHER WARRANTIES EXCEPT THAT OF TITLE,
WHETHER WRITTEN, ORAL OR IMPLIED, IN FACT OR IN LAW
(INCLUDING ANY WARRANTY AGAINST INFRINGEMENT OR
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE).
These warranties give you specific legal rights, and you may also
have other rights which vary from state to state.
DEXTER HEREBY EXCLUDES INCIDENTAL AND
CONSEQUENTIAL DAMAGES, INCLUDING LOSS OF TIME,
INCONVENIENCE, LOSS OF USE, TOWING FEES, TELEPHONE
CALLS, COST OF MEALS OR LODGING, FOR ANY BREACH
OF ANY EXPRESS OR IMPLIED WARRANTY.
Some states do not allow limitations on how long an implied
warranty lasts, or the exclusion or limitation if incidental or
consequential damages, so the above exclusion or limitation may
not apply to you.
Inquiries regarding these warranties should be sent to:
Dexter Axle Company
P.O. Box 250
Elkhart, IN 46515
Note: Current publication “Operation Maintenance Service Manual”
can be found at www.dexteraxle.com.
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Axle Identification
In the unlikely event that you should require service assistance
from Dexter, please have the lot (serial) number of the axle
available when you call.
On all axles produced after April 2001, this nine digit number can
be found near the center on the rear side of the axle beam. Look
for the words DEXTER AXLE and the lot number will be located
directly under the name. For easier identification, rubbing a piece
of chalk over the number may help bring out the engraving.
Recreational Vehicle axles that have been certified for use in
Canada will also bear the letters CSA.
Axle Identification
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Dexter Online Parts Store
From magnets and seals to complete brake and hub kits, Dexter offers a
complete line of genuine replacement parts for your trailer. Most products
are available in-stock and ready to ship within 24 hours direct to you from
the factory. With dedicated customer support and quick turnaround, the
Dexter Online Parts Store helps keep your trailer going.
• Hub Components
• Brake Components
• Suspension Components
• Complete Hub Kits
• Brake Assemblies & Kits
• Brake Controllers & Actuators
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Dexter Video Gallery
In keeping with our continual commitment to industry safety and the
development of innovative products, please feel free to view our ongoing
video gallery at www.dexteraxle.com/resources/videos or scan the
following QR codes. We are confident these videos will help educate and
promote the Dexter product line that you, as our customer, are investing
in.
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Service Record
Date Service Performed Mileage
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Service Record
Date Service Performed Mileage
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Service Record
Date Service Performed Mileage
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Notes
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Notes
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Notes
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Genuine Dexter axles and components are available
nationwide from our plant locations listed below or
through our network of distributors. Check our web site
for the distributor nearest you.
Dexter Headquarters
Plants 12, 13, 39, 61
UFP
UFP Plant 25
Plant 24
Plants 15, 62
Plant 21
Dexter - Headquarters
2900 Industrial Parkway East Elkhart, Indiana 46516
Phone: 574-295-7888 Fax: 574-295-8666
www.dexteraxle.com